Managing big data in process control systems

• US 10,656,627 B2
• Filed: 04/28/2017
• Issued: 05/19/2020
• Est. Priority Date: 01/31/2014
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Nixon, Mark J., Muston, Paul Richard, Chen, Deji, Han, Song
• Primary Examiner(s): Anya, Charles E
• Application Number:
  US15/582,194
• Publication Number:
  US 20170235298A1
• Time in Patent Office: 1,117 Days
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 2219/31462 Add time stamp to alarm message
• CPC Class Codes: G05B 23/0264 Control of logging system, e.g. decision on which data to store; time-stamping measurements

Abstract

A big data network or system for a process control system or plant includes a data storage device configured to receive process control data from control system devices and store the process control data. The big data network or system identifies various parameters or attributes from the process control data, and creates and uses rowkeys to store the parameters according to various combinations, such as combinations using timestamps. The big data network or system may also store certain aggregate data analyses associated with time periods specified by the timestamps. Accordingly, the big data network or system efficiently stores real-time data having measurements within a database schema, and users or administrators can leverage the aggregate data to analyze certain data associated with certain time periods.

Claims

1. A method of accessing process control data associated with a process control plant, the method comprising:

receiving a request from a user to retrieve a portion of process control data stored in a data storage device, the process control data corresponding to at least one process that is controlled by a plurality of devices in the process control plant, wherein the request indicates a set period of time;

retrieving, from the data storage device, the portion of the process control data corresponding to the set period of time, the portion of the process control data including a plurality of records, each record of the plurality of records having (1) a respective process variable, (2) a measurement value associated with the respective process variable, and (3) a respective remainder portion of a respective timestamp that falls within the set period of time, the respective timestamp including a respective rounded timestamp portion and the respective remainder timestamp portion, and the each record accessed via a rowkey, wherein the rowkey includes (i) an indication of the respective process variable and (ii) an indication of the respective rounded timestamp portion of the respective timestamp;

generating, by a processor, aggregate process control data from the plurality of records; and

presenting the aggregate process control data to the user.

2. The method of claim 1, wherein generating the aggregate process control data comprises:

arranging the plurality of records according to at least one statistical parameter associated with the each record of the plurality of records.

3. The method of claim 1, wherein generating the aggregate process control data comprises:

calculating at least one statistical parameter from the plurality of records, wherein the aggregate process control data indicates the at least one statistical parameter.

4. The method of claim 1, wherein generating the aggregate process control data comprises:

receiving a selection of at least one statistical parameter from the user; and

generating the aggregate process control data to indicate the at least one statistical parameter.

5. The method of claim 1, further comprising:

receiving an additional request from the user to modify the aggregate process control data, the additional request indicating an additional set period of time occurring within the set period of time;

identifying a portion of the plurality of records that falls outside of the additional set period of time;

modifying the aggregate process control data by removing the portion of the plurality of records that falls outside of the additional set period of time; and

presenting the modified aggregate process control data to the user.

6. The method of claim 1, further comprising:

receiving an additional request from the user to modify the aggregate process control data, the additional request indicating an additional set period of time at least partly occurring outside the set period of time;

retrieving, from the data storage device, an additional portion of the process control data corresponding to the additional set period of time, the additional portion of the process control data including a plurality of additional records;

modifying the aggregate process control data by adding the plurality of additional records; and

presenting the modified aggregate process control data to the user.

7. The method of claim 1, wherein generating the aggregate process control data comprises:

generating aggregate process control data from the plurality of records having the same respective process variable.

8. A system of accessing process control data associated with a process control plant, comprising:

one or more data storage devices configured to store process control data corresponding to at least one process that is controlled by a plurality of devices in the process control plant;

a user interface adapted to receive a request from a user to retrieve a portion of the process control data, wherein the request indicates a set period of time; and

one or more processors adapted to interface with the one or more data storage devices and the user interface and configured to;

retrieve, from the one or more data storage devices, the portion of the process control data corresponding to the set period of time, the portion of the process control data including a plurality of records, each record of the plurality of records having (1) a respective process variable, (2) a measurement value associated with the respective process variable, and (3) a respective remainder portion of a respective timestamp that falls within the set period of time, the respective timestamp including a respective rounded timestamp portion and the respective remainder timestamp portion, and the each record accessed based on a rowkey, wherein the rowkey includes (i) an indication of the respective process variable and (ii) an indication of the respective rounded timestamp portion of the respective timestamp;

generate aggregate process control data from the plurality of records; and

cause the user interface to present the aggregate process control data to the user.

9. The system of claim 8, wherein the one or more processors generate the aggregate process control data by:

arranging the plurality of records according to at least one statistical parameter associated with the each record of the plurality of records.

10. The system of claim 8, wherein the one or more processors generate the aggregate process control data by:

calculating at least one statistical parameter from the plurality of records, wherein the aggregate process control data indicates the at least one statistical parameter.

11. The system of claim 8, wherein the one or more processors generate the aggregate process control data by:

receiving, from the user via the user interface, a selection for at least one desired statistical parameter, and

generating the aggregate process control data to indicate the at least one statistical parameter.

12. The system of claim 8, wherein the user interface is further adapted to receive an additional request from the user to modify the aggregate process control data, the additional request indicating an additional set period of time occurring within the set period of time;

and wherein the one or more processors are further configured to;

identify a portion of the plurality of records that falls outside of the additional set period of time,

modify the aggregate process control data by removing the portion of the plurality of records that falls outside of the additional set period of time, and

cause the user interface to present the modified aggregate process control data to the user.

13. The system of claim 8, wherein the user interface is further adapted to receive an additional request from the user to modify the aggregate process control data, the additional request indicating an additional set period of time at least partly occurring outside the set period of time;

and wherein the one or more processors are further configured to;

retrieve, from the one or more data storage devices, an additional portion of the process control data corresponding to the additional set period of time, the additional portion of the process control data including a plurality of additional records,

modify the aggregate process control data by adding the plurality of additional records, and

cause the user interface to present the modified aggregate process control data to the user.

14. The system of claim 8, wherein the one or more processors generate the aggregate process control data by:

generating aggregate process control data from the plurality of records having the same respective process variable.

15. A process control system, comprising:

a controller configured to control a process in the process control system;

a field device communicatively connected to the controller, the field device configured to perform a physical function to control the process in the process control system, and the field device configured to transmit to or receive from the controller real-time data corresponding to the physical function; and

a process control system big data apparatus, the process control system big data apparatus including;

one or more data storage devices configured to store the real-time data,

a user interface adapted to receive a request from a user to retrieve a portion of the real-time data, wherein the request indicates a set period of time, and one or more processors adapted to interface with the one or more data storage devices and the user interface and configured to;

retrieve, from the one or more data storage devices the portion of the process control data corresponding to the set period of time, the portion of the process control data including a plurality of records, each record of the plurality of records having (1) a respective process variable, (2) a measurement value associated with the respective process variable, and (3) a respective remainder portion of a respective timestamp that falls within the set period of time, the respective timestamp including a respective rounded timestamp portion and the respective remainder timestamp portion, and the each record accessed via a rowkey, wherein the rowkey includes (i) an indication of the respective process variable and (ii) an indication of the respective rounded timestamp portion of the respective timestamp;

generate aggregate process control data from the plurality of records; and

cause the user interface to present the aggregate process control data to the user;

wherein the controller is a first node of a process control system big data network, and the process control system big data apparatus is a second node of the process control system big data network.

16. The process control system of claim 15, wherein the one or more processors generate the aggregate process control data by:

arranging the plurality of records according to at least one statistical parameter associated with the each record of the plurality of records.

17. The process control system of claim 15, wherein the one or more processors generate the aggregate process control data by:

calculating at least one statistical parameter from the plurality of records, wherein the aggregate process control data indicates the at least one statistical parameter.

18. The process control system of claim 15, wherein the user interface is further adapted to receive an additional request from the user to modify the aggregate process control data, the additional request indicating an additional set period of time occurring within the set period of time;

and wherein the one or more processors are further configured to;

identify a portion of the plurality of records that falls outside of the additional set period of time,

modify the aggregate process control data by removing the portion of the plurality of records that falls outside of the additional set period of time, and

cause the user interface to present the modified aggregate process control data to the user.

19. The process control system of claim 15, wherein the user interface is further adapted to receive an additional request from the user to modify the aggregate process control data, the additional request indicating an additional set period of time at least partly occurring outside the set period of time;

and wherein the one or more processors are further configured to;

retrieve, from the data storage device, an additional portion of the process control data corresponding to the additional set period of time, the additional portion of the process control data including a plurality of additional records,

modify the aggregate process control data by adding the plurality of additional records, and

cause the user interface to present the modified aggregate process control data to the user.

20. The process control system of claim 15, wherein the one or more processors generate the aggregate process control data by:

generating aggregate process control data from the plurality of records having the same respective process variable.